Apparatus and method for spraying flock



2 Sheets-Sheet 1 C.- M. DAVIS ET AL March 26, 1957 APPARATUS AND METHOD FOR SFRAYING FLOCK Filed Nov. 10, 1955 s WC m w 5 N I m 7 V 7 8 m .MW. 7 W p ufi l 2 m G I l- Y 0% B a M aw m a f 2 y 4 I 4/ 4 5 lr i March 26, 1957 c. M. DAVIS ETAL 2,786,721

APPARATUS AND METHOD FOR SPRAYING FLOCK 2 Sheets-Sheet 2 Filed Nov. 10, 1955 States atent 2,786,721 Patented Mar. 26, 1957 APPARATUS AND METHOD FOR SPRAYING FLOCK Carl M. Davis and Gordon Miter, Riverside, Calif.; said Miter assignor to said Davis Application November 10, 1955, Serial No. 550,510

4 Claims. (Cl. 302-52) (Filed under Rule 47(a) and 35 U. S. C. 116) This invention relates to the art of applying flock to various objects, including Christmas trees. More particularly, the invention relates to a method and apparatus for separating masses of flock into particulate form and conducting the particulated flock through a conduit to a discharge point, such as adjacent a Christmas tree on which adhesive is being simultaneously sprayed so that the tree becomes covered with flock and the appearance of snow is given.

Flock, which may be defined as very short fibers of cotton, wool, vegetable matter, etc., is normally shipped and stored in relatively compacted masses which are not in condition for application to a surface. In order to apply the flock to a surface to be coated, whether such surface be a wall, a panel, or an object .such as a Christmas tree, the relatively wadded mass must first be separated into particulate form and then conducted to a convenient point of application to the surface, such as by a hose or other conduit.

In employing previous methods and apparatus for applying fiock to surfaces a number of problems have been encountered, a very important problem being created due to the tendency of the flock particles to ball up and clog the hose through which they are passed such as by an air blast. It may be seen that in order to spray flock successfully, without frequent interruptions for removal of balls from the dock conduit, it is not only necessary to provide means for initially separating the flock from the relatively large mass thereof, but also for maintaining the separated flock in finely divided form such that no clogging of the conduit can occur. It is to be understood that even if the ball or small mass of flock is not sufliciently large to clog the conduit, so that it passes therethrough, such balling or wadding .is extremely undesirable in that it prevents even application of flock to the surface being sprayed.

In view of these and other factors characteristic of present flocking equipment and methods, it is an object of the present invention to provide a method and apparatus for applying flock to objects without resulting in the formation of balls or wads such as would either clog conduit elements or result in uneven application of flock to the surface.

Another object of the invention is to provide a flocking machine incorporating improved means for maintaining the flock in particulate condition after its separation from the relatively large mass in which it was shipped or stored prior to use.

A further object is to provide a highly simple, economical and reliable apparatus for separating particles of flock from a mass thereof and maintaining such particles turbulent prior to introduction thereof into a con duit through which they are to be passed, so that there is no possibility of balling or wadding of the particles to either block the conduit or result in uneven application of the flock to an object being sprayed.

These and other objects andadvantages of the invention will be more fully set forth in the following specification and claims, which are to be considered in connection with the attached drawings to which they relate.

In the drawings:

Figure l is a perspective side view of a flocking ma: chine embodying the present invention;

Figure 2 is a top plan view of the showing of Figure 1, illustrating the perforated drum contained within the hopper;

Figure 3 is a vertical central sectional view taken along line 3-3 of Figure l, as viewed in the direction of the arrows;

Figure 4 is an enlarged fragmentary perspective view of the drive elements which are illustrated at the left in Figures 1 and 2;

Figure 5 is an enlarged fragmentary sectional view of the turbulence chamber, the section being taken along line 55 of Figure 3 and showing the air nozzle in a retracted position effecting maximum turbulence;

Figure 6 corresponds to Figure 5, but shows the air nozzle in an inner position effecting a decreased amount of turbulence; and

Figure 7 is an enlarged detail sectional view of the air nozzle.

Referring to the drawings, and particularly to the Figure 1 thereof, the flocking machine may be seen to comprise generally a hopper 10 which is supported above the ground by any suitable means such as a supporting frame 11. Rotatably mounted within the hopper 10 is a fl0ckfeeding means 12 in the form of a perforated drum. Upon rotation of the drum 12 by motor means indicated at E3, particles of flock separate from the flock mass contained in the drum and pass downwardly through the perforations into a turbulence chamber indicated at 14 in Figures 3, 5 and 6. The particulate flock is then blown, by an air blast from an adjustable air nozzle 16, out of the turbulence chamber 14 and through a flock and air nozzle 17 for transmission through a conduit 18 to a point of application.

'It is to be understood that the conduit 13 may serve to conduct the flock particles to a number of objects such as walls or panels, or to a Christmas tree which is being sprayed for the purpose of simulating snow. In the latter application, for example, a suitable adhesive may be sprayed on portions of the tree at substantially the same time as flock is sprayed thereon from the conduit 18, so that the particles of flock stick to the tree in the desired manner. The apparatus for spraying the adhesive may be of any suitable type and is accordingly not shown or described in the present application. It is to be understood that no nozzle whatsoever need be incorporated with the unshown end of conduit 18.

in greater detail, hopper 10 is formed with a cylindrical upper portion 21 connected with a conoidal lower portion 22, the latter being elongated (as viewed in horizontal section) in order to provide smooth access for the flock particles into the relatively long and narrow turbulence chamber 14. The turbulence chamber is formed with generally rectangular vertical side walls 23 which connect at their lower edges to a V-sectioned trough 24. One end wall of turbulence chamber 14 is formed. as a vertical wall 26 having at the trough end a triangular lower portion, the latter having an internally threaded bushing 27 (Figure 7) welded therein for reception of the air nozzle 15 which preferably comprises an externally threaded hollow rod. The air nozzle 16 is horizontally disposed along the bottom of trough 24 and lies in a vertical plane which is located midway between the vertical side walls 23 of the turbulence chamber.

The other end wall of the turbulence chamber has a rectangular upper portion 28 which merges adjacent the top of trough 24 with an outwardly projecting rounded portion 29. The latter is connected with an extension 3 of trough 24, and cooperates therewith to form the walls of the flock and air nozzle 17. The nozzle 17 converges into a tubular spout portion 31 over which one end of flock conduit 18 is mounted.

The perforated flock-feeding drum 12 is formed with imperforate end walls in which is non-rotatab'ly secured, in horizontal axially-extending relationship, a shaft 32. The shaft 32 is journaled in suitable bearings 33 which are formed not only in the cylindrical hopper portion 21 but also in the upper part of supporting frame 11, the latter being shown as comprising two angularly-related side elements. The drum 1.2 is formed on one side thereof with an opening over which is hingedly mounted a door 34. When the drum is rotated with shaft 32 so that door 34 is uppermost, the door may be pivoted about its hinges after unbuckling of a clasp 36 and in order to introduce a mass of flock into the drum. It is to be understood that such flock is normally sold in bags and in a relatively compacted condition, necessitating that it be converted into particulate condition upon rotation of the drum 12 and prior to passage of the flock into turbulence chamber 14.

The motor means 13 is mounted on a horizontal platform 37 on frame 11, and comprises a pneumatic motor 3% connected to a gear-reduction unit 39. The output shaft of the reduction unit 39 has a pulley 41 (Figure 4) mounted thereon and encompassed by a belt 42 leading to one of a plurality of different diameter pulleys 43 on a projecting end of drum shaft 32. Operation of the pneumatic motor 38 to drive reduction unit 39 thus effects rotation of shaft 32 and perforated drum 12, in accordance with the speed of the motor and in accordance with the diameter of the pulley 43 around which belt 42 is mounted.

The air-circuits associated with the motor means 13 and with adjustable nozzle 16 comprise an inlet air hose 44 leading from a suitable air compressor (not shown) to the manifold or header 46 shown in Figure 4. The header is provided with three valved outlets 47-49, the first of which 47 connects to a hose 51 leading to the inlet of pneumatic motor 38. The second valved outlet 43 connects to a hose 52 leading to the outer end of nozzle 16, and the third valved outlet 49 is an auxiliary which is provided for connection to any suitable device as desired.

In carrying out the method of the invention, particles of flock are first separated from a mass thereof and permitted to fall, due to the effect of gravity, toward an inlet to a conduit through which it is desired to conduct the particles. An air blast is then directed both toward the inlet to the conduit and generally upwardly into the falling particles, so that a turbulent area is formed which prevents balling or wedding of the particles into masses which might clog the conduit or prevent even applica tion of the flock onto a surface being coated.

In greater detail, and with the apparatus illustrated in the drawings and described above, the method comprises placing a mass of flock in the flock-feeding drum 12 by first opening the door 34 and then, for example, emptying into the drum a bag in which the flock was shipped and stored. The door 34 is then closed and clasp 36 is secured, after which the operator causes compressed air to flow through inlet hose 44 to header 46. Assuming that valved outlets 47 and 48 are open, air then flows through hose 51 to pnetunatic motor 38, thus operating through gear reducer 39, belt 42 and pulleys 41 and 43 to rotate the shaft 32 and drum 12 thereon at a predetermined speed. Air also flows from valved outlet 48 through hose 52 to the outer end of adjustable nozzle rod 16.

Rotation of the drum 12 causes the mass of flock to gravitates in particulate form downwardly through the conoidal portion 22 of hopper and into turbulence chamber 14. In so doing, the flock tends to hang up on the hopper sides and form 'masseswhich, when they suddenly release, might result in the described balling and wadding of the flock conduit.

Referring first to Figure 5, in which the outlet of nozzle rod 16 is shown as being relatively close to chamber wall 26, the major portion of the air blast from the rod in passes along trough 24 and through air and flock nozzle 1'7 into conduit 18. However, a substantial portion of the air from nozzle 16 also passes upwardly into the upper portion of turbulence chamber 14, and creates an agitation effect which breaks up any masses of falling flock and prevents forming of balls or wads in the flock conduit.

Referring next to Figure 6, the air nozzle 16 is shown as adjusted inwardly to a position at which its discharge end is relatively adjacent the inlet of air and flock nozzle 17. A much greater proportion of the air blast thus enters nozzle 17, but a substantial amount of air still flows upwardly into the upper portion of turbulence chamber 14 to create the desired agitation effect.

The air nozzle 16 is adjusted in accordance with the type of flock used, the desired amount of air flow through conduit 18, and other factors, it being understood that suflicient turbulence should always be maintained to break up any masses of flock that form after the flock particles leave the feeding drum 12, so that no clogging of the conduit results.

Various embodiments of the present invention, in addition to the one illustrated, may be employed without departing from the scope of the accompanying claims.

We claim:

1. Apparatus for applying flock particles evenly to surfaces of objects, which comprises a hopper, means to define a turbulence chamber at the lower portion of said hopper, an air and flock nozzle leading outwardly from said turbulence chamber for connection to a flock conduit, an air inlet nozzle leading into said turbulence chamber and directed toward said air and flock nozzle, said air inlet nozzle being spaced sufficiently far from said air and flock nozzle to permit a substantial portion of the air from said air inlet nozzle to flow upwardly into said turbulence chamber and maintain in turbulent condition particles of flock falling therethrough, a perforated drum mounted in said hopper and adapted to receive a mass of flock, and means to rotate said drum to feed flock in particulate form through the perforations thereof for gravitation into said turbulence chamber.

2. The invention as claimed in claim 1, in which said last-named means includes an air motor connected to the source of air pressure for said air inlet nozzle.

3. The invention as claimed in claim 1, in which said air inlet nozzle is axially adjustable toward and away from said air and flock nozzle.

4. Apparatus for applying flock to a surface, which comprises a hopper, a perforated container adapted to contain flock and to discharge the same into said hopper, means to rotate said container to effect flow of flock particles through the perforation thereof and into said hopper, and means to conduct said flock particles to said surface.

References Cited in the file of this patent UNITED STATES PATENTS 289,984 Corkill Dec. ll, 1883 1,333,079 Kaufmann Mar. 9, 1920 1,653,631 Kirkland Dec. 27, 1927 1,783,487 Weiss Dec. 2, 1930 1,970,405 Thomas Aug. 14, 1934 FOREIGN PATENTS 261,584 Germany June 24, 1913 

